Integrated viscous transmission in a differential

ABSTRACT

A differential drive for use on a vehicle to control the transfer of torque between the front and rear axles of a vehicle. The differential drive includes a rotatably driven differential housing supported in a housing. The differential drive also includes a differential gear set arranged and supporting in the differential housing. The differential gear set has at least two side shafts gears and at least two differential gears. The differential drive also includes a torque distribution device having a viscous transmission. The viscous transmission has an inner hub and an outer casing. The inner hub is connected to a first side shaft. The outer casing is connected to one of the side gears. The viscous transmission also connects the output of the first side shaft to one of the side shaft gears.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of application Ser. No. 09/678,718 filed on Oct.4, 2000 now U.S. Pat. No. 6,248,439.

TECHNICAL FIELD

The present invention relates to differential drives for a motorvehicle, and more particularly, relates to a speed sensing torquetransfer device for use in a vehicle.

BACKGROUND ART

The differential drive is well known in the motor vehicle industry. Thedifferential drive is used in conjunction with the transmission anddrive shaft or propeller shaft (prop shaft) to turn the automotivevehicle wheels at different speeds when the vehicle is going around acurve, to differentiate the speed of each wheel individually and toprovide the proper amount of torque to each wheel in slipping, turningor other road to wheel conditions.

In a traditional torque on demand drive train layout of an automotivevehicle, there is a primary driven front/rear axle and a secondarydriven hang-on axle that is connected via prop shaft or drive shaft anda torque transferring coupling to the primary driven axle. The torquetransfer coupling is usually directly in front of the secondary drivenaxle. The axle differential creates the division of power or torque toeach side shaft of the axle. The primary driven axle also includes adifferential which divides the necessary power to the side shaft of eachfront axle and then the wheels. The division of torque between the frontand rear axle is completed by the torque transfer coupling which is aseparate unit on the drive train system and requires spacing for itshousing and other related parts. A current state-of-the-art passivetorque transfer coupling for an automotive vehicle is located betweenthe primary and secondary driven axles of the vehicle and can generallyconsist of a viscous coupling, gear rotor coupling, or any other passivespeed sensing device. The viscous coupling unit senses slip conditionsof the wheels, monitors current driving conditions of the vehicle anddistributes torque to each wheel or axle as necessary.

A passive torque transfer system provides flexibility in thedistribution of torque between the axles in an all-wheel or four-wheeldrive automotive system. Generally, a passive speed sensing device willprovide traction control through a smooth and progressive torquetransfer to the wheel or axle with the greatest traction potential. Theviscous coupling is a well known passive speed sensing device thatoperates according to principles of fluid friction and thus is dependenton speed differences. Furthermore, the viscous coupling has greatflexibility in its design parameters thus allowing it to achieve desiredtorque characteristics with relation to traction and handling. Theviscous coupling is a self contained unit that does not need electronicsor remote sensors to operate. All of these passive speed sensing torquedrive systems are located in a separate housing usually directly infront of the rear differential.

Therefore, there is a need in the art for a device to simplify, reducethe weight and required space of a passive speed sensing torquedistribution device for use in an automotive vehicle.

DISCLOSURE OF THE INVENTION

One object of the present invention is to provide an improved torquedistribution device. Another object of the present invention is toprovide a torque distribution device that includes a viscoustransmission that runs at axle speed, which will reduce imbalance issuesin the transaxle.

Yet a further object of the present invention is to reduce and minimizethe packaging requirements in the prop shaft area of the automotivevehicle.

Still another object of the present invention is to provide adifferential that includes a viscous transmission that runs in oil andalso reduces the effort for bearings and seals while improving thecooling of the differential.

A further object of the present invention is to reduce the number ofinterfaces in the drive train while also reducing the weight and cost ofthe drive train assembly.

Still a further object of the present invention is to integrate withinthe existing axle housing the viscous transmission to control the torquebetween the front and rear axles.

To achieve the foregoing objects the differential drive for use on avehicle includes a rotatably driven differential housing supported in ahousing. A differential gear set arranged and supporting in thedifferential housing. The differential gear set including at least twoside shaft gears and at least two side gears. A torque distributiondevice having a viscous transmission. The viscous transmission having aninner hub and an outer casing. The inner hub being connected to a firstside shaft. The viscous transmission also includes an outer casing thatis connected to one of the side shaft gears. The viscous transmissionconnects the output of the first side shaft to one of the side shaftgears.

One advantage of the present invention is a new and improved torquedistribution device for a vehicle.

A further advantage of the present invention is that the torquedistribution device uses a viscous transmission that runs at axle speedwhich reduces imbalance issues on the drive train.

A further advantage of the present invention is the reduced or minimizedpackaging requirement in the prop shaft area of the motor vehicle.

Yet a further advantage of the present invention is the inclusion of theviscous transmission that runs in oil to reduce the effort for bearingsand seals while also improving the cooling within the differential.

A further advantage of the present invention is to reduce the number ofinterfaces and reduce the weight and costs of distributing torque to thedrive train system.

A further advantage of the present invention is the integration withinthe housing of the viscous transmission for the torque distributiondevice.

Other objects, features, and advantages of the present invention willbecome apparent from the subsequent description and appended claimstaken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic view of a vehicle system according to thepresent invention.

FIG. 2 shows a schematic view of a prior art vehicle drive train system.

FIG. 3 shows a schematic view of a vehicle drive train system accordingto the present invention.

FIG. 4 shows a cross section of a differential drive according to thepresent invention.

BEST MODE OF CARRYING OUT THE INVENTION

As shown in FIG. 4, there is a torque distribution device 10 accordingto the present invention. FIG. 1 schematically illustrates an all wheeldrive or four wheel drive motor vehicle 12 that is a primary front wheeldriven vehicle, however, the present invention can also be used on aprimary rear wheel drive driven vehicle as well.

The motor vehicle 12 as shown in FIG. 1 is primarily driven by a frontaxle system 15. The motor vehicle 12 is an all wheel drive or four wheeldrive vehicle and is driven by power transferred from the engine 16through a transaxle or gear box 18, which may be either automatic or amanual gear box. The power from the gear box 18 enters the power takeoff20 of the drive train assembly and finally on through to the frontdifferential 30. When there is a demand for power, power is transferredto the rear differential 22 via a propeller shaft or driving shaft 24.At the rear differential 22 power splits to a left rear side shaft 28and a right rear side shaft 26 for distribution to the wheels at therear of the vehicle 12. The front differential 30 controls power andslip or spin from the left front side shaft 34 and the right front sideshaft 32. In an all wheel drive vehicle, power is delivered to both therear differential 22 and front differential 30 via a distributing drive,but either the front axle system 15 or the rear axle system 14 is aprimarily driven axle, with the other axle only receiving power whenneeded. The preferred embodiment of the present invention is anall-wheel drive vehicle wherein the torque distribution device 10 islocated within the rear differential 22 and operates from there todistribute torque to the front and rear axles of the vehicle 12.

FIG. 2 shows the drive train 36 of a prior art vehicle. The drive train36 includes a front axle system 38 which includes a right front sideshaft 40 and a left front side shaft 42. A propeller shaft or driveshaft 44 transmits the power from the power takeoff 46 to the reardifferential 48. The rear differential 48 has a right rear side shaft 50and a left rear side shaft 52 extending therefrom to the vehicle wheelswhich will propel the vehicle in a forward or reverse motion. Thepropeller shaft 44 is connected to the torque coupling housing 54 whichis in front of the rear differential 48 in the prior art system. Thetorque coupling housing 54 then connects to the rear differential drivewhich includes an axle housing 56 in which a differential housing isrotatably supported around a rotation axis. The differential housing isdriven by the vehicle gear box via a driving gear. As noted the torquecoupling housing 54 is located outside and in front of the reardifferential 22 in the prior art all wheel drive system. The torquecoupling runs at prop shaft torque and prop shaft speed which sometimescomplicates packaging issues for the automotive designer. The packagingrequires a large separate housing to hold the torque coupling whichrequires more material and is a more expensive mounted torque couplingwhen it is externally mounted in front of the rear differential 48.

FIG. 3 shows a drive train 58 of an all wheel drive vehicle 12 accordingto the present invention. The drive train 58 includes a front axlesystem 15 which includes a right front side shaft 32 and a left frontside shaft 34. A propeller shaft or drive shaft 24 transmits power fromthe power take off 20 to the rear differential 22. The rear differential22 has a right rear side shaft 26 and the left rear side shaft 28extending therefrom to the vehicle wheels which will drive the vehiclein a forward or reverse motion. The rear differential drive 22 includesan axle housing 76 in which a differential housing 80 is rotatablysupported around a rotational axis. The differential housing 80 isdriven by the vehicle gear box via a driving gear 81. The torquedistribution device 10 of the current invention is located within thedifferential housing 80 and is used to transfer torque between the frontaxle system 15 and the rear axle system 14 as shown. The use of thetorque distribution device 10 within the differential drive 22 inconjunction with an open differential will reduce the weight and cost ofthe vehicle by removing the need for a separate torque transfer couplingor viscous transmission, which is usually located directly in front ofthe rear differential drive 22. The incorporation of the torque transferdevice 10 within the differential drive 22 greatly reduces the spacerequired on the undercarriage of the vehicle leaving more space forexhaust and fuel tank needs. Furthermore, it reduces any noise,vibration and harshness issues associated with having a separate housingmounted in front of the rear differential 22.

FIG. 3 shows a rear differential 22 which includes the axle housing 76which rotatably supports the differential housing 80 around a rotationalaxis. FIG. 4 shows the differential housing 80. The differential housing80 includes a differential gear set 82 that is rotatably arranged andsupported therein. In the preferred embodiment, the differential gearset 82 is a standard bevel or planetary set. The gear set 82 generallyincludes two differential bevel gears or differential gears 84 that arerotatably arranged on a bearing pin 86 whose axis forms a rotationalaxis for the two differential bevel gears 84. The rotational axis forthe differential bevel gears 84 will intersect the rotational axis forthe differential side shaft gears 88 and 90 within the differentialhousing 80. Differential side shaft gears 88 and 90 are arranged arounda rotational axis as to be rotatable relative to the differentialhousing 80. Differential side shaft gears 88 and 90 are rotatablyreceived in bores 92 of the differential housing 80. Differential sideshaft gears or side shaft gears 88 and 90 are supported against theinner face of the differential housing 80 with supporting disks 94arranged therebetween. The axis of rotation of the side shaft gears 88and 90 and the axis of rotation of the differential gears 84 intersecteach other at a right angle. As shown in FIG. 3, the propeller or driveshaft 24 engages the differential housing 80 via a driving gear 81.

The torque distribution device 10 is located within the differentialhousing 80 and engages the differential gear set 82. The torquedistribution device 10 will connect one of the differential side shaftgears 88 with one of the side shafts 28. The torque distribution device10 includes a passive speed sensing device which in the preferredembodiment is a viscous transmission 96 as shown in FIG. 4. It should benoted that any other type of passive speed sensing device can be usedsuch as a gear rotor pump, clutch pack and shear pump, etc. The viscoustransmission 96 includes an inner hub 98 and an outer casing 100. Theouter casing 100 includes two walls 102, 104 on each end thereof. Theouter casing 100 also includes on an inner surface a plurality of teeth106. The inner hub 98 of the viscous transmission includes a pluralityof teeth 108 on its inner surface. The inner hub 98 is connected on aside opposite teeth 108 to the side shaft 28 of the rear differential22. The viscous transmission 96 also includes on one wall thereof a seal110 to keep the viscous fluid within the viscous transmission chamber112 which is formed by the two walls of the outer casing 100 and innerhub 98. Extending within the operating chamber 112 of the viscoustransmission 96 are outer plates 114 and inner plates 116 which arearranged in a certain sequence along the longitudinal axis of theviscous transmission 96. The outer plates 114 are associated with theviscous outer casing 100 and engage the teeth 106 of the outer casing ofthe viscous transmission 96. Spacing rings 118 will space the outerplates 114 relative to one another and relative to the viscoustransmission outer casing 100. The inner plates 116 are arranged betweenthe outer plates 114. The inner plates 116 include circumferentiallydistributed teeth 120 which clip on to and engage the teeth 108 locatedon the inner hub 98. The inner plates 116 are movable along thelongitudinal axis of the viscous transmission 96.

The operating chamber 112 of the viscous transmission 96 is partiallyfilled with a viscous fluid, for example, a highly viscous silicone oil.If a speed differential occurs between the inner hub 98 and the outercasing 100 of the viscous transmission 96, a speed difference will alsooccur between the outer plates 114 and the inner plates 116 of theviscous transmission. Any speed difference that is sensed between theinner and outer plates 116, 114 will create a viscous shear within theviscous transmission and thus transfer torque while in the normaloperating viscous mode. As the shearing force of the viscous fluidincreases the inner and outer plates 114, 116 interact with one anotherforcing the inner hub 98 to spin at the speed of the side gear 88 whichis connected to the outer casing 100 of the viscous transmission 96.This increases the power or torque to the side shaft 28 and the sideshaft 26 via the open differential. Thus, torque will be transferred tothe rear wheels of the vehicle during a slip condition of the frontprimary driven wheels.

In operation the differential gear set 82 takes the speed differencebetween the front and rear axle 15, 14 and between the left and righthand wheels of the secondary driven rear axle at the same time. This alloccurs while the viscous transmission 96 is running at the same speed asthe axle speed and providing the torque transfer to one of the sideshafts and then onto a wheel. The second side shaft gear 90, connectedside shaft 26 and wheel is then driven with the same torque via the opendifferential. Therefore, the differential 22 is an open differentialbetween the left and right side shafts 26, 28 of the rear axle 14allowing the wheels to spin freely in a turn. The torque distributiondevice 10, as described, above controls the slip between the front andrear axles 14, 15 of the automotive vehicle by controlling one of theside shafts 28 of the secondary driven axle 14. This removes the needfor a separate torque transfer coupling which is generally locateddirectly in front of the prop shaft usually in front of the reardifferential.

When a spin condition affects the front wheels, the front wheels rotatethe prop shaft faster which will rotate the differential housing 80faster which in turn will rotate the differential gear set andconsequently the side gear 88 faster. The increase in the rotationalvelocity at the side gear 88 will cause the outer casing 100 of theviscous transmission 96 to rotate faster along with the connected outerplates 114. The rotation of the outer plates 114 will create a shearingeffect within the viscous fluid of the viscous transmission 96. Thisinteraction of the inner and outer plates 116, 114 of the viscoustransmission, via the viscous shear, will create greater torque androtation of the inner hub 98 of the viscous transmission 96 which willpass that greater torque and speed to side shaft 28 thus providingtorque and spinning power to the rear wheels over the open differential,when the front wheels are in a spin condition. When the spin conditionis over, the front wheels will grip the surface of the road thus sendingless torque through the prop shaft 24 to the rear differential 22, henceslowing down the velocity sent to the rear differential 22 and in turnslowing down the rotation of the differential housing 80 until anequilibrium is reached and the viscous transmission fluid reaches anequilibrium. This equilibrium will reduce the torque being passedthrough the inner and outer plates 114, 116 to the side shaft 28 of therear axle. The equilibrium will allow for free rotation of the rear sideshafts at the equilibrium point and not deliver any torque to the rearwheels. Therefore, any speed difference between the front and rear axles14, 15 will cause a slip speed difference across the viscoustransmission 96 and generate torque or power to the rear wheels. Theslip speed across the viscous transmission 96 is generally twice thespeed difference between the front and rear axle differential case.

The new improved torque distribution device 10 as described abovecreates several advantages over the prior art including the viscoustransmission 96 running with and at axle speed which will reduce theimbalance issues within the drive train system. The minimized packagingrequirements of the prop shaft area also increases room needed forexhaust and fuel tank purposes. The torque distribution device 10 alsoreduces the effort needed for bearings and seals by being incorporatedinto the differential housing 80. The differential oil also will improvecooling of the torque distribution device 10. The combination andinclusion of the torque distribution device 10 within the differentialdrive also reduces the number of interfaces needed from the differentialdrive 22 to the power distribution portion of the drive train assembly.Furthermore, there is a reduction in weight because the torque transfercoupling housing is no longer necessary and this also reduces costs bytooling fewer parts.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

What is claimed is:
 1. A differential drive for use on a vehicle, saiddifferential drive including: a rotatably driven differential housingsupported in a housing; a differential gear set arranged and supportedin said differential housing; and a torque distribution device adjacentto said differential gear set within said differential housing, saidtorque distribution device including a passive viscous speed sensingunit, said torque distribution device connecting one output of a sideshaft with one output of a side shaft gear, said torque distributiondevice is arranged to control torque between a front axle system and arear axle system of the vehicle.
 2. The differential drive of claim 1wherein said differential gear set includes two side shaft gearsarranged and supported in said differential housing.
 3. The differentialdrive of claim 2 wherein said differential gear set further includes atleast two differential gears which engage said side shaft gears and arerotatably supported in said differential housing.
 4. The differentialdrive of claim 1 wherein said differential gear set obtains a speeddifference between said front and rear axle systems.
 5. The differentialdrive of claim 1 wherein said passive speed sensing unit rotates withaxle speed and provides torque transfer to a first side shaft.
 6. Thedifferential drive of claim 5 wherein a second side shaft gear is drivenwith said same torque via said differential gear set.
 7. Thedifferential drive of claim 6 wherein said differential gear operates asan open differential between said first and said second side shaftgears, said open differential allows vehicle wheels to spin freely. 8.The differential drive of claim 1 wherein a speed difference betweensaid rear and said front axle creates slip across said passive speedsensing unit which generates torque.
 9. The differential drive of claim8 wherein said slip across said passive speed sensing unit isapproximately twice said speed difference between said front and rearaxle.
 10. The differential drive of claim 1 wherein said viscoustransmission runs in oil which reduces effort for bearings and sealswhile improving cooling of the differential drive.
 11. A differentialdrive for use on a vehicle to control the transfer of torque betweenfront and rear axle systems of the vehicle, said differential driveincluding: a rotatably driven differential housing supported in ahousing; a differential gear set arranged and supported in saiddifferential housing, said differential gear set having at least twoside shaft gears and at least two differential gears; and a torquedistribution device including a viscous transmission arranged withinsaid differential housing, said viscous transmission having an inner huband an outer casing, said inner hub connected to a first side shaft,said outer casing connected to a side shaft gear; and said viscoustransmission connects output of said first side shaft to one of saidside shaft gears.